Method for fabricating a simplified CMOS polysilicon thin film transistor and resulting structure

ABSTRACT

A method of forming a MOS device using doped and activated n-type and p-type polysilicon layers wherein a first doped and activated polysilicon layer (either n-type and p-type) is patterned on a substrate. An isolation material layer is formed abutting the first doped and activated polysilicon layer in the corners formed at the junction between the first doped and activated polysilicon layer and the substrate. A second doped and activated polysilicon layer (either n-type or p-type) is applied over the first doped and activated polysilicon layer and the isolation material layer. The second doped and activated polysilicon layer is planarized to the height of the first doped and activated polysilicon layer. The first and second doped and activated polysilicon layers are etched to substantially bifurcate the first and second doped and activated polysilicon layers. Further processing steps known in the art are utilized to complete the MOS device. The method of the present invention eliminates ion implantation and annealing steps used in present methods.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of application Ser. No. 08/900,906, filed Jul.28, 1997, now U.S. Pat. No. 6,140,160.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for fabricating a Complementary Metal Oxide Semiconductor (“CMOS”) Thin Film Transistor (“TFT”). More particularly, the present invention relates to fabricating a CMOS TFT with a simplified method which eliminates the ion implantation and annealing steps used in present methods.

2. State of the Art

The development of new portable electronic products, such as notebook computers and personal interface devices, is currently receiving a great deal of attention in the consumer products market. Substantial research and development have been focused in the field of active matrix liquid-crystal displays. Active matrix displays generally consist of flat panels of liquid crystals or electroluminescent materials which are switched “on” and “off” by electric fields. Every liquid crystal picture element (“pixel”) is charged by thin film transistors (“TFTs”). One of the most common components in the circuit for the liquid crystal display is the inverter, which has a CMOS structure constructed with a pair of n-type and p-type TFTs.

Although both polysilicon and amorphous silicon may be used in the fabrication of TFTs, a polysilicon semiconductor layer generally provides greater mobility of electrons and holes than does amorphous silicon. Furthermore, the CMOS structure can be easier to construct with polysilicon since the n-type and p-type TFTs can be formed by the same implant and anneal process. The CMOS inverter constructed with polysilicon TFTs also offers excellent characteristics in terms of operating frequency and power consumption.

In the fabrication of a TFT, the semiconductor-layer source and drain regions are formed by introducing an impurity element into the semiconductor layer (see U.S. Pat. No. 5,514,879 issued May 7, 1996 to Yamazaki). The controlled introduction of impurities enable good transistor characteristics. Typically, the introduction of impurities for a CMOS TFT requires two masking and implantation steps. As shown in FIG. 26, a substrate 202 is coated with a layer of oxide 204. A non-doped polysilicon layer 206 is applied to the oxide layer 204, and a resist layer 208 is applied to the non-doped polysilicon layer 206 in a predetermined pattern. The non-doped polysilicon layer 206 is then etched to form a non-doped polysilicon ledge 210, as shown in FIG. 27. A portion of the non-doped polysilicon ledge 210 is masked with a first mask 212 and an n-type impurity is introduced into the unmasked portion of the non-doped polysilicon ledge 210 to form an n-type area 214, as shown in FIG. 28. The first mask 212 is removed and a second mask 216 is applied to the non-doped polysilicon ledge 210 so as to cover the n-type area 214 and a portion 220 of the non-doped polysilicon ledge 210. A p-type impurity is introduced to the unmasked portion of the non-doped polysilicon ledge 210 to form a p-type area 218, as shown in FIG. 29. The second mask 216 then is removed to form a fundamental CMOS TFT gate structure 222 with the portion 220 acting as an insulating barrier between the n-type area 214 and the p-type area 218, as shown in FIG. 30.

The impurities can be introduced by thermal diffusion or ion implantation. By using thermal diffusion, the impurities are introduced from the surface of the semiconductor layer. By using ion implantation, impurity ions are implanted into the semiconductor layer. The ion implantation method provides a more precise control with respect to the total impurity concentration and depth that the impurities can be implanted into the semiconductor layer, and thus allows impurities to be implanted into a shallow, thin film. Furthermore, ion implantation can be performed at low temperatures. For the above reasons, ion implantation is a preferred technique for introducing impurities into a semiconductor layer in the fabrication process of the TFT.

In the above-described fabrication process of the TFT, impurities are implanted by a conventional ion implantation apparatus using an ion beam having a diameter of only several millimeters. When the ions are to be implanted over a large substrate using the above conventional ion implantation apparatus, it is necessary to either move the substrate mechanically or scan the ion beam electrically over the substrate since the area of the substrate is larger than the diameter of the ion beam. The necessity of having a mechanical moving means for the ion beam causes a problem in that the ion implantation apparatus becomes complicated, large, and expensive.

One technique for solving the above problem, wherein ions can be easily implanted into a large area, is an ion shower-doping method. According to this technique, ions generated by using a plasma discharge are dispersed in a cone shape and accelerated at a low voltage without mass separation to implant in the substrate. Although this technique allows ions to be implanted simultaneously over a large portion of the entire semiconductor layer, it does not result in uniform implantation.

Once the implantation is complete, the structure is annealed at about 600° C. to activate the impurities. However, the temperature of annealing is detrimental to any temperature-sensitive portion of the entire structure.

Therefore, it would be advantageous to develop a technique to form a CMOS TFT which eliminates the need for introducing impurities during the fabrication of the CMOS TFT, while using state-of-the-art semiconductor device fabrication techniques employing known equipment, process steps, and materials.

SUMMARY OF THE INVENTION

The present invention relates to a method for fabricating a CMOS TFT using doped and activated n-type and p-type polysilicon layers, which eliminates ion implantation and annealing steps used in present methods.

In one embodiment of the present invention, the CMOS TFT is constructed by first coating a base substrate with a layer of oxide. A pre-doped and pre-activated n-type polysilicon layer is applied over the oxide layer. A resist layer is applied to the n-type polysilicon layer such that when the n-type polysilicon layer is etched and the resist layer is removed, n-type regions are formed. An isolation material layer is then applied over the oxide layer and the n-type regions. The isolation material layer is etched such that a portion of the isolation material layer, which resides in the corners formed at the junction between the oxide layer and the n-type regions, forms isolation caps. A pre-doped and pre-activated p-type polysilicon layer is then applied over the oxide layer, n-type region, and isolation caps.

The p-type polysilicon layer is then planarized down to form the p-type regions having a height substantially equal to that of the n-type regions. The p-type regions and the n-type regions are isolated from one another by the isolation caps, hereafter referred to as the isolation barriers. It is, of course, understood that the p-type layer may be applied to the oxide layer prior to applying the n-type layer.

The n-type regions and p-type regions may alternately be formed by again coating a substrate with a layer of oxide. A pre-doped and pre-activated n-type polysilicon layer is applied to the oxide layer. A pad oxide is applied over the n-type polysilicon layer and a nitride layer is applied over the pad oxide to form a layered assembly. A resist layer is patterned on the nitride layer. The layered assembly is etched and the resist layer removed to form an n-type region stack. The nitride layer is then removed and a thin layer of silicon dioxide is formed over the n-type polysilicon layer. A pre-doped and pre-activated p-type polysilicon layer is then applied over the oxide layer and the thin layer of silicon dioxide. The p-type polysilicon layer is then planarized down to the height of the n-type region to form -type regions, wherein the thin silicon dioxide layer may act as a planarization stop. The p-type and the n-type regions are isolated from one another by the portions of the thin silicon dioxide layer, which become the isolation barriers.

Once the p-type and n-type regions (separated by the isolation barriers) are fabricated, resist masks are formed over each isolation barrier such that open areas are positioned over the n-type regions and the p-type regions. The n-type regions and the p-type regions are then simultaneously etched and the resist masks removed such that the n-type region and the p-type region are each substantially bifurcated into n-type areas and p-type areas, respectively.

A layer of semiconductive, undoped material is disposed over the exposed portions of the oxide layer, the n-type areas, the p-type areas, and the isolation barriers. A layer of insulative material is placed over the semiconductive, undoped material. A layer of metal gate material is then placed over the insulative material layer. A layer of barrier oxide is then disposed over the metal gate material layer.

The barrier oxide layer is masked and etched down to each of the n-type areas, the p-type areas, and the isolation barriers to form gates. An isolation material is applied over the gates, the n-type areas, the p-type areas, and the isolation barriers. The isolation material is etched, leaving end caps abutting edges of the gates.

A layer of passivation material is disposed over the gates, the n-type areas, the p-type areas, and the isolation barriers. The passivation layer is then masked and etched to expose a portion of the n-type areas, the p-type areas, and the isolation barriers.

Poly plugs are disposed within the etched areas in the passivation layer to contact the n-type areas, the p-type areas, and the isolation barriers to form a CMOS TFT structure. Thus, the entire CMOS TFT structure is built with only four mask steps with the n-type and p-type areas being formed by two of these mask steps, which eliminates time-consuming, multiple masking steps required by known fabrication techniques. This, in turn, reduces the cost of manufacturing the CMOS TFT.

As discussed above, the present invention utilizes deposited layers of pre-doped and pre-activated n-type and p-type polysilicon layers. However, it is understood that ion implant steps can be used to vary device characteristics.

Furthermore, it is, of course, understood that, although the present invention is described in terms of a CMOS TFT, the techniques can be applied to other MOS structures such as PMOS and NMOS structures.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming that which is regarded as the present invention, the advantages of this invention can be more readily ascertained from the following description of the invention when read in conjunction with the accompanying drawings in which:

FIGS. 1-15 are side cross-sectional views of a CMOS TFT fabrication technique of the present invention;

FIG. 16 is an electrical schematic of a CMOS TFT;

FIGS. 17-19 are side cross-sectional views of an alternate gate formation method for a CMOS TFT fabrication technique of the present invention;

FIGS. 20-25 are side cross-sectional views of a method of forming n-type and p-type regions of the present invention; and

FIGS. 26-30 are side cross-sectional views of a prior art method of fabricating a CMOS TFT.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 through 15 illustrate a preferred method of the present invention for forming a CMOS TFT. As shown in FIG. 1, abase substrate 102, such as a semiconductor substrate, glass substrate, or the like, is coated with a layer of oxide 104, such as silicon dioxide. An n-type polysilicon layer 106, which has previously been doped and activated, is applied to the oxide layer 104. A resist layer 108 is applied to the n-type polysilicon layer 106 in a predetermined pattern. The n-type polysilicon layer 106 is etched and the resist layer 108 removed to form an n-type region 110, as shown in FIG. 2. An isolation material layer 112, preferably silicon dioxide or silicon nitride, is applied over the oxide layer 104 and the n-type region 110, as shown in FIG. 3. The isolation material layer 112 is etched, leaving isolation caps 114 abutting edges 116 of the n-type region 110, as shown in FIG. 4. Optionally, a thin layer of silicon dioxide 118 can be deposited or grown (e.g., by thermal oxidation) over the oxide layer 104, n-type region 110, and isolation caps 114, as shown in FIG. 5. The thin layer of silicon dioxide 118 is used to prevent contamination and act as an etch stop during subsequent processing. A p-type polysilicon layer 120, which has been doped and activated, is then applied over the oxide layer 104, n-type region 110, and isolation caps 114, or over the thin layer of silicon dioxide 118 if formed, as shown in FIG. 6.

The p-type polysilicon layer 120 is then planarized down to the n-type region 110 wherein the thin silicon dioxide layer 118 may act as a planarization stop. Planarization ensures that the n-type polysilicon layer 106 and the p-type polysilicon layer 120 will be on the same horizontal plane, similar to a twin-tub process. This planarization forms p-type regions 122 and is preferably achieved using an abrasive process such as chemical mechanical planarization (“CMP”). The p-type regions 122 and the n-type region 110 are isolated from one another by the isolation caps 114 and such portions of the thin silicon dioxide layer 118 as may exist. This combination will hereafter be referred to as isolation barriers 124, as shown in FIG. 7.

The n-type regions 110 and p-type regions 122 may alternately be formed by the process illustrated in FIGS. 20-25. As shown in FIG. 20, a substrate 160, such as a glass substrate or the like, is coated with a layer of oxide 162. An n-type polysilicon layer 164 which has previously been doped and activated is applied to the oxide layer 162. A pad oxide 166 is applied over the n-type polysilicon layer 164 and a mask layer 168, preferably a nitride layer, is patterned over the pad oxide 166 to form a layered assembly 170. The layered assembly 170 is etched to form an n-type region stack 174, as shown in FIG. 21. The mask layer 168 is removed, as shown in FIG. 22. If the mask layer 168 is a nitride layer, it is preferably removed with phosphoric acid at about 155° C. A thin layer of silicon dioxide 176 can be deposited or grown over the n-type polysilicon layer 164, as shown in FIG. 23. A p-type polysilicon layer 178, which has been doped and activated, is then applied over the oxide layer 162 and the thin layer of silicon dioxide 176, as shown in FIG. 24.

The p-type polysilicon layer 178 is then planarized down to the n-type polysilicon region 164 wherein the thin silicon dioxide layer 176 may act as a planarization stop. This planarization forms p-type regions 180. The p-type regions 180 and the n-type polysilicon region 164 are isolated from one another by non-etched portions 182 of the thin silicon dioxide layer 176, as shown in FIG. 25. It is, of course, understood that the order of forming the n-type polysilicon regions 164 and the p-type regions 180 is not important. Thus, the p-type polysilicon layer 178 may be formed first followed by n-type polysilicon layer 164.

As shown in FIG. 8, once the p-type and n-type regions (separated by the isolation barriers) are fabricated, resist masks 126 are formed over each isolation barrier 124 such that open areas 128 are positioned over the n-type regions 110 and the p-type regions 122. The n-type regions 110 and the p-type regions 122 are simultaneously etched and the resist masks 126 removed to form n-type regions 110 and p-type regions 122 that are each substantially bifurcated into n-type areas 130 and p-type areas 132, as shown in FIG. 9.

As shown in FIG. 10, a layer of undoped semiconductive material 134, preferably undoped polysilicon, is disposed over the exposed portions of the oxide layer 104, the n-type areas 130, the p-type areas 132, and the isolation barriers 124. A layer of insulative material 136 is placed over the undoped semiconductive material layer 134. A layer of conductive gate material 138 is then placed over the insulative material layer 136. A layer of barrier oxide or nitride 140 is then disposed over the conductive gate material layer 138. The conductive gate material 138 is preferably planarized, such as by CMP, prior to the deposition of the barrier oxide/nitride layer 140. It is, of course, understood that the conductive gate material may be comprised of metal, metal alloys, conductive polymer material, or a layered combination of both.

The barrier oxide layer 140 is masked and etched down to each of the n-type areas 130, the p-type areas 132, and the isolation barriers 124, as shown in FIG. 11, to form gates 142. An isolation material (not shown), preferably silicon dioxide or silicon nitride, is applied over the gates 142, the n-type areas 130, the p-type areas 132, and the isolation barriers 124. The isolation material is spacer etched, leaving end caps 144 abutting edges 146 of the gates 142, as shown in FIG. 12.

A layer of passivation material 148, such as a low eutectic glass (e.g., borophosphosilicate glass or “BPSG”) or other material known in the art, is disposed over the gates 142, the n-type areas 130, the p-type areas 132, and the isolation barriers 124, as shown in FIG. 13. The passivation layer 148 is then masked and etched to exposed a portion of the n-type areas 130, a portion of the p-type areas 132, and the isolation barriers 124, as shown in FIG. 14.

As shown in FIG. 15, metal or poly plugs 150, preferably doped polysilicon, are disposed within the etched areas in the passivation layer to contact the n-type areas 130, the p-type areas 132, and the isolation barriers 124, thus forming a CMOS TFT structure 152, which comprises an NMOS (N-type Metal Oxide Semiconductor) section 190 and a PMOS (P-type Metal Oxide Semiconductor) section 192. The CMOS TFT structure 152 forms the CMOS TFT circuit 154 shown in FIG. 16.

An alternate method for gate fabrication is illustrated in FIGS. 17-19. Elements common between FIGS. 1-15 and FIGS. 17-19 retain the same numeric designation. After the formation of the n-type areas 130 and p-type areas 132 (separated by isolation barriers 124) on the oxide layer 104, as shown in FIG. 9, a layer of undoped semiconductor material is deposited over the structure shown in FIG. 9. The layer of undoped semiconductor material is then planarized to form undoped semiconductor material plugs 194 between the n-type areas 130 and p-type areas 132, as shown in FIG. 17. A layer of insulative material 136 is placed over the undoped semiconductive material plugs 194, the n-type areas 130, the p-type areas 132, and the isolation barriers 124. A layer of conductive gate material 138 is then placed over the insulative material layer 136. A layer of barrier oxide or nitride 140 is then disposed over the conductive gate material layer 138, as shown in FIG. 18. The barrier oxide layer 140 is masked and etched down to each of the n-type areas 130, the p-type areas 132, and the isolation barriers 124, as shown in FIG. 19, to form gates 142. A CMOS TFT is formed from the structure shown in FIG. 19 in a similar manner as illustrated in FIGS. 12-15.

As discussed above, the present invention utilizes deposited layers of pre-doped and pre-activated n-type and p-type polysilicon layers. However, it is understood that the above process can be complimented by ion implant and anneal steps to vary device characteristics.

Having thus described in detail preferred embodiments of the present invention, it is to be understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description as many apparent variations thereof are possible without departing from the spirit or scope thereof.

It is, of course, understood that the above described technique can be used to form an NMOS TFT by replacing the p-type polysilicon layer 120 with an n-type polysilicon layer and to form a PMOS TFT by replacing the n-type polysilicon layer 106 with a p-type polysilicon layer. 

What is claimed is:
 1. A method for forming an activated area for a MOS structure, comprising: providing a semiconductor substrate with an active surface; forming a first layer comprising doped polysilicon of a first conductivity type over said active surface; patterning said first layer to form a first polysilicon area; forming an isolation barrier laterally adjacent said first polysilicon area and abutting said first polysilicon area in a corner formed at a junction between said first polysilicon area and a surface of a layer or structure upon which said first polysilicon area is located; and forming a second layer comprising doped polysilicon of a second conductivity type laterally adjacent said isolation barrier.
 2. The method of claim 1, further comprising forming a layer comprising an oxide over said active surface.
 3. The method of claim 2, wherein said forming said layer comprising said oxide is effected before said forming said first layer comprising doped polysilicon, said patterning said first layer, said forming said isolation barrier, and said forming said second layer comprising doped polysilicon.
 4. The method of claim 1, wherein said patterning said first layer comprises: disposing a mask on said first layer; etching said first layer through said mask to form said first polysilicon area; and removing said mask.
 5. The method of claim 1, wherein said forming said isolation barrier comprises: applying a layer comprising isolation material over said semiconductor substrate and said first polysilicon area; and removing regions of said layer comprising isolation material such that a portion of said layer remains at least in said corner at said junctions between said surface of said layer or structure upon which said first polysilicon area is located and said first polysilicon area.
 6. The method of claim 1, wherein said patterning said first layer and said forming said isolation barrier comprise: forming a layer comprising silicon oxide over said first layer; forming a layer comprising silicon nitride over said layer comprising silicon oxide; disposing a mask on said layer comprising silicon nitride; removing portions of said layer comprising silicon nitride, said layer comprising silicon oxide, and said first layer through at least one of said mask and an overlying layer to form said first polysilicon area; removing said mask; removing said layer comprising silicon nitride; and forming a layer comprising isolation material over at least exposed, lateral edges of said first layer comprising doped polysilicon, said isolation material in a portion of said layer abutting a corner at a junction between said first polysilicon area and a surface of a layer or structure upon which said first polysilicon area is located forming said isolation barrier.
 7. The method of claim 1, further comprising: planarizing said second layer to form a second polysilicon area laterally adjacent said isolation barrier.
 8. The method of claim 1, wherein said forming said first layer comprising polysilicon comprises forming said first layer comprising polysilicon to have a p-type conductivity.
 9. The method of claim 1, wherein said forming said first layer comprising polysilicon comprises forming said first layer comprising polysilicon to have an n-type conductivity.
 10. The method of claim 1, wherein said forming said second layer comprises forming said second layer with at least polysilicon having a p-type conductivity.
 11. The method of claim 1, wherein said forming said second layer comprises forming said second layer with at least polysilicon having an n-type conductivity.
 12. A method for fabricating activated areas of a MOS structure, comprising: forming at least one first layer comprising doped polysilicon of a first conductivity type on a surface of a layer or structure on a substrate; patterning said at least one first layer to form a first polysilicon area; forming at least one isolation barrier laterally adjacent said at least one first layer comprising doped polysilicon; and forming at least one second layer comprising doped polysilicon of a second conductivity type laterally adjacent said at least one isolation barrier, opposite said at least one first layer comprising polysilicon.
 13. The method of claim 12, further comprising patterning said at least one second layer to form at least one second polysilicon area that is electrically isolated from said one first polysilicon area.
 14. The method of claim 12, wherein said patterning said at least one first layer comprises: disposing a mask on said at least one first layer; and removing regions of said at least one first layer through said mask.
 15. The method of claim 12, wherein said forming said at least one isolation barrier comprises: applying an isolation material layer over said substrate active surface and said at least one first polysilicon area; and removing regions of said isolation material layer such that a portion of said isolation material layer remains laterally adjacent said at least one first polysilicon area.
 16. The method of claim 12, wherein said patterning said at least one first layer comprising doped polysilicon and said forming said at least one isolation barrier comprise: applying an oxide layer over said at least one first layer; applying a nitride layer over said oxide layer; disposing a mask on said nitride layer; etching portions of said nitride layer, said oxide layer, and said at least one first layer through at least one of said mask and an overlying layer to form said at least one first polysilicon area; removing said mask; removing said nitride layer; and forming an isolation material layer over at least exposed, lateral edges of said first polysilicon area, at least a portion of said isolation material layer forming said at least one isolation barrier.
 17. The method of claim 13, further comprising: forming at least one mask so as to shield said at least one isolation barrier and portions of said first polysilicon area and said at least one second polysilicon area that are laterally adjacent thereto; and substantially simultaneously etching said first polysilicon area and said at least one second polysilicon area through said at least one mask.
 18. The method of claim 12, wherein said forming said at least one first layer comprises forming said at least one first layer with polysilicon having a p-type conductivity.
 19. The method of claim 12, wherein said forming said at least one first layer comprises forming said at least one first layer with polysilicon having an n-type conductivity.
 20. The method of claim 12, wherein said forming said at least one second layer comprises forming said at least one second layer with polysilicon having a p-type conductivity.
 21. The method of claim 12, wherein said forming said at least one second layer comprises forming said at least one second layer with polysilicon having an n-type conductivity.
 22. The method of claim 17, further comprising removing said at least one mask.
 23. The method of claim 17, further comprising fabricating at least one gate comprising semiconductive material over said first polysilicon area, said at least one second polysilicon area, and said at least one isolation barrier.
 24. The method of claim 23, further comprising disposing a passivation layer over said at least one gate. 